Stopped for gas and bike won't start.

Kill switch?

Thanks! Got the manual. Now I'm even more confused.

I shined a flashlight (not a torch) in the gas tank while hitting the switch and didn't see any cavitation or signs of activity as in R-III-R Turbo's linked post above.

Instead of the nice arrangement of 3 relays as shown in the manual:


I have two, bodged together with gaff tape and free dangling:



Additionally, that connector below them in the manual has had one of its wires snipped and replaced with a butt connector:





Reportedly the first owner installed a Power Commander, so this could have something to do with that?

I tried swapping the relays and, not knowing what that second relay is, it didn't work at all - even the noise the pump was making didn't occur. Which leads me to wonder about the condition of that lefthand relay... The fan, if that's what it is, was fine the ride before last (didn't notice if it came on Saturday). If it's the ECM relay, that could explain the failure to start, but then where the heck is the fan relay?

idk said:

Kill switch?

Click to expand...

Sorry, you posted while I was organizing the photo exhibition above. If it's turning over, none of the kill switches- clutch, kickstand, neutral, tilt - should be in play, right?

The plug you circled in green and with the cut wire is for the purge control valve for the fuel tank evap canister (used to control the opening of the fuel tank purge valve). Most of us have already removed the canister and disconnected the plug as it is not needed (except to satisfy the tree huggers). Not sure of the 05 model but you should have three relays and they should be mounted with the wires on the bottom so as to keep water out of the relay. Did you say you have a clicking noise from the pump but the pump is not pressurizing the injectors? If so, you might have a bad pump. You can disconnect the wire from the fuel pump (under the tank) and see if you are getting voltage to the pump (with the key on) using a multimeter. On my bike it would be the purple/white wire. Also check the ground (black) wire for a good ground. You can also spray a little starter fluid or gas (carefully and with fire extinguisher handy) into the throttle bodies then hit the start switch and see if it will fire off.

if those relays have been hanging down. we have heard from other members that they fill up with water and also rust. relays fail

Thank all you guys! IDK's manual let me figure out how to get under the tank and gave me much needed reference, and leatal's lead (no pun intended) to the purple/white wire let me verify that the fuel pump was not getting power. Then, being only a partial moron, I had a moment of clarity and realized the "missing" relay was actually mounted to the bracket where it was supposed to be. When I tried the relay swap earlier it had been with the EMS relay and, of course, the bike wasn't going to start without that. With the fan relay in place: boom goes the dynamite!

Hopefully Engle will have the relay in stock and I'll be rolling tomorrow. Never been so happy to pay $25 for a relay!

I'm pretty sure that Turbo200r4 hit it on the head. Whoever left it like that tried to mitigate issues by swathing it in gaff tape and glomming it full of dielectric grease - which has its own issues - but I'm going to try to find the original rubber mounting sleeves or, barring that, mount them on the bracket with heavy duty velcro - the plastic on plastic kind I used to mount big ole' CB radios with.

Pardon my shambolic garage, but please join me in enjoying this sweet, sweet, music!

I would check a relay first!

Turbo is spot on pump isn’t right. Sorry I didn’t listen to the sound clip earlier, you can clearly hear it go through the throttle body test with no pump prime.

And another happy ending!

Glad you got it sorted, congrats!